WO2005084904A1

WO2005084904A1 - Multilayer dose

Info

Publication number: WO2005084904A1
Application number: PCT/IB2005/050708
Authority: WO
Inventors: Jacques Thomasset
Original assignee: Aisapack Holding S.A.
Priority date: 2004-03-01
Filing date: 2005-02-26
Publication date: 2005-09-15
Also published as: ES2350188T3; RU2352459C2; CA2557590C; DE602005022983D1; US20070184223A1; CN1926027B; HK1097486A1; BRPI0508338A; BRPI0508336A; JP2007525349A; WO2005087473A1; JP2007525348A; JP2007527806A; EP1720692A1; CA2557616A1; KR20070003942A; CN1925961B; JP2007525347A; WO2005084902A1; CA2557622A1

Abstract

The invention relates to a multilayer synthetic resin dose for producing multilayer objects by compression moulding comprising an axis of symmetry and consisting of a first synthetic resin (2) and at least one thin functional layer (3) of synthetic resin forming the external envelop of a body of rotation which is defined around said axis of symmetry and comprises two ends disposed in a direction parallel to the axis of symmetry .The inventive dose is characterised in that the functional layer (3) is entrapped in the first synthetic resin entirely or in such a way that not more than one end is entrapped in said first resin.

Description

Multilayer dose

Field of the invention

The present invention relates to a method of producing multilayer objects by compression molding a multilayer dose.

State of the art

US Pat. No. 4,876,052 describes a cylindrical multilayer dose (FIG. 1) characterized in that a functional resin 3 is completely trapped inside a synthetic resin 2. The functional resin and the outer resin are of different nature. . For example, the functional resin has high gas barrier properties, while the resin forming the outer layer is chosen for its mechanical and hygienic properties. These multilayer doses make it possible to obtain multilayer objects by compression molding said dose. However, the objects obtained according to the method described in US Pat. No. 4,876,052 require a large proportion of functional resin in the object; which generates two major disadvantages; the former being a prohibitive cost and the second a resistance to mechanical stress diminished. The absence of adhesion between the functional resin and the external resin reduces the solidity of the object and creates a risk of cohesion of the outer layer. Another disadvantage of US Pat. No. 4,876,052 is that the respective amount of resins 2 and 3 can only be slightly adjusted; these quantities being fixed by the geometry of the object and by the flows during compression of the dose.

Japanese patent JP 2098415 proposes to produce a multilayer object by compression molding starting from a cylindrical dose (FIG. 2), characterized in that the synthetic resin 2 only covers the lateral faces of the functional resin 3. The compression molding of this dose along its axis of symmetry leads to an object having a multilayer structure characterized by the fact that the synthetic resin 2 partially traps the resin 3. However, the multilayer objects made from two resins according to JP 2098415 have several major disadvantages; the first being to have the functional resin 3 exposed in the central surface of the object on at least 10% of the total surface of the object; and the second being to require an amount of functional resin 3 in the subject of at least 30% of the total amount of resin. This leads on the one hand to objects having a prohibitive cost, and on the other hand to objects with highly modified mechanical properties mainly in the center of the object. Another disadvantage of patent JP 2098415 resides in the fact that the respective quantity of resins 2 and 3 can only be slightly adjusted, these quantities being fixed by the geometry of the object and the flows during compression of the dose. . The JP 2098415 patent has a final major disadvantage is that the two resins are found at least partially on the surface of the object, which poses hygiene problems depending on the resins used.

It is proposed in JP 2098415 to use a cylindrical dose comprising 3 layers (Figure 3) to partially overcome the aforementioned drawbacks. This dose consists of a first resin forming the central part of the dose, a functional resin 3 covering only the lateral faces of the first resin, and a third resin 2 covering only the lateral faces of the functional resin. The crushing of this composite dose along its axis of symmetry leads to a multilayer object. The use of a tri-layer dose has the advantage of reducing the amount of functional resin 3 used and leads to objects having weakly modified mechanical properties compared to the same object comprising a single resin 2. This method makes it possible to add an adhesive layer between resins of different types; therefore the cohesion and strength of the object is improved. However, the functional resin 3 does not cover the central part of the multilayer object which leads to objects without barrier property close to the axis of symmetry over an area of at least 10% of the surface of the object. This central zone of the object not covered by the barrier resin layer 3 reduces the barrier performance of the object and makes this solution less efficient. JP 2098415 has a final major drawback which is the fact that the three resins are found at least partially on the surface of the object, which poses hygiene problems depending on the resins used.

Object of the invention

The present invention makes it possible to produce multilayer objects by compression molding by remedying the aforementioned problems.

Summary of the invention

The invention consists of a multilayer dose having an axis of symmetry for producing multilayer objects by compression molding, said dose consisting of a first synthetic resin and at least one thin functional layer forming the surface of a body revolution; said functional layer being trapped in the first resin; the multilayer dose being characterized in that at most one end of said layer is not trapped in the first resin.

The invention is particularly useful for producing multilayer objects intended to be used in the field of packaging and more particularly in the food field where standards of hygiene are high.

The invention describes multilayer doses which make it possible to obtain packaging or packaging components having a functional layer totally absent from the surface of the wall of the package being in contact with the packaged product.

According to a first embodiment of the invention, the thin functional layer 3 is totally trapped in the resin 2 forming the dose. The multilayer object obtained is characterized in that the functional layer 3 is totally trapped in the wall of said object, so that only the resin 2 is present on the surface of said object. According to a second embodiment of the invention, the thin functional layer 3 is totally trapped except for one of its ends, said end being apparent on the surface of said dose. The multilayer object obtained; having an inner face and an outer face; is characterized in that the functional layer 3 is at least absent from one of the faces of the object.

The method for obtaining multilayer doses is described in the present invention.

Detailed description of the invention

The invention will be better understood hereinafter by means of a detailed description of the examples illustrated by the following figures.

Brief description of the figures

Figures 1 to 3 describe the multilayer doses described in the prior art for making multilayer objects by compression molding.

FIG. 1 shows a bilayer dose made according to US Pat. No. 4,876,052

Figure 2 shows a bilayer dose used in JP 2098415.

Figure 3 illustrates a 3-layer dose described in JP 2098415.

FIG. 4 shows a first example of a multilayer dose corresponding to the first embodiment of the invention. This cylindrical dose comprises a thin functional layer 3 of resin, totally trapped inside the resin 2 forming the dose. FIG. 5 illustrates a multilayer object made from the compression in a mold of the dose illustrated in FIG. 4. The functional layer 3 forms a fold and is completely absent from the surface of the object.

FIG. 6 illustrates a multilayer dose corresponding to the second embodiment of the invention. This cylindrical dose comprises a thin functional layer of resin 3, having an end 5 which is not trapped inside the resin 2 forming said dose.

FIG. 7 illustrates a multilayer object obtained from the compression in a mold of the dose illustrated in FIG. 6. The functional resin layer 3 is trapped in the resin 2, except its end 5 which is flush with the outer surface 11 of said object.

FIG. 8 illustrates another example of a multilayer dose produced according to the first embodiment of the invention. This tubular dose is formed of a thin functional layer 3 completely trapped inside the resin 2 forming said dose.

FIG. 9 shows a tube shoulder obtained by compression in a mold of the dose shown in FIG. 8. The functional layer 3 is totally absent from the surface of said tube shoulder.

FIG. 10 illustrates another example of a multilayer dose produced according to the second embodiment of the invention. This tubular dose is formed of a thin functional layer 3 partially trapped inside the resin 2 forming said dose. The end 5 of the functional layer 3 is present on the surface of the dose.

Figure 11 shows a tube shoulder obtained by compression in a mold of the dose shown in Figure 10. The functional layer 3 is totally absent from the inner surface 10 of said tube shoulder; said inner face being in contact with the packaged product. The functional layer 3 is partially present on the outer surface of the tube shoulder.

Figures 12, 13, 14 and 15 show other examples of multilayer dose corresponding to the invention.

Figure 16 shows a first method for making doses according to the first embodiment of the invention.

Figure 17 illustrates another method for making doses according to the first embodiment of the invention.

Figure 18 shows a method for making doses corresponding to the second embodiment of the invention.

Figure 19 illustrates another method for making doses according to the second mode.

Detailed description of the figures

The invention describes advantageous multilayer doses for producing multilayer objects and in particular packaging or packaging components. For hygienic reasons, it is often desirable that the packaged product not be in direct contact with the functional resins. Functional resins may be barrier resins that are used to provide gas or aroma impermeability properties, or adhesive resins that are used to associate multiple resins.

The invention describes multilayer doses which make it possible to obtain packaging or components of packaging that can be used in the food field; the functional layer 3 being totally absent from the surface of the package which is in contact with the packaged product. According to a first mode of the invention, it has been found that a dose having a thin functional layer 3 completely trapped in a first resin 2 was particularly advantageous for producing multilayer objects having high hygienic properties. The multilayer object obtained is characterized in that the functional layer 3 is totally trapped in the wall of said object, so that only the resin 2 is present on the surface of said object.

According to a second embodiment of the invention, the thin functional layer 3 is totally trapped except at one of its ends, said end being apparent on the surface of said dose. The multilayer object obtained by the compression of the dose in a mold; has an inner face and an outer face; and is characterized in that the functional layer 3 is at least absent from one of the faces of the object.

A wide variety of multilayer doses can be made according to the invention. The said doses may be of the cylindrical or tubular type, or of more complex geometry.

The invention also relates to methods for producing said doses.

The invention also describes multilayer objects obtained by compression molding said doses.

FIG. 4 illustrates a multilayer dose corresponding to the first embodiment of the invention. This dose 1 consists of a thin layer of functional resin 3 trapped in a resin 2. The thin layer of functional resin 3 has two free ends 4 and 5 located inside the resin 2; said ends being separated from the surface of said dose by a distance 6, 7 sufficient so that these ends are also absent from the surface of the molded object. The functional layer 3 is disposed in the dose so that said layer 3 is distributed throughout the molded object without said layer 3 appearing on the surface of said object. Figure 4 illustrates a dose in which the Functional layer describes the envelope of a cylinder centered on the axis of symmetry of the dose. This dose has the advantage of being easily manufactured.

The functional layer 3 ideally represents a small part of the volume of the dose or the object; the volume of the layer 3 being generally less than 20% of the total volume, and preferably less than 10%.

FIG. 5 shows the multilayer object obtained from compression in a mold of the dose shown in FIG. 4. This object comprises the thin functional layer 3 totally trapped in the wall of said object; said layer 3 forming a fold close to the periphery of said object; said fold and said ends 4 and 5 being totally trapped in said object.

The relationship between the position of the thin layer 3 in the dose and in the object is defined by the multilayer flow during compression of said dose in the mold.

It has been found that the position of the fold of the functional layer 3 in the object depends on the radial position of the layer 3 in said dose; when the layer 3 approaches the periphery of the dose, the fold of the layer 3 approaches the periphery of the object. If the layer 3 is too close to the periphery of the dose, we find a portion of the layer 3 on the surface of the object. There is therefore an optimal position of the layer 3 in said dose, which leads to the propagation of the layer 3 and the formation of a fold near the periphery of the object; said layer 3 remaining trapped in the object.

It has also been found that the position of the ends 4 and 5 of the functional layer 3 in the object depend little on the flows during compression. Also, it has been observed that it is difficult to trap in the object the ends of the functional layer 3 when it is not trapped in the dose. Conversely, it has been found that when the ends 4 and 5 of the functional layer 3 are absent from the surface of the dose, these are also absent from the surface of the object. It has also been observed that was sufficient for a very small distance between the ends of the layer 3 and the surface of the dose so that these are absent from the surface of the object. Distances 6 and 7, between the ends of the layer 3 and the surface of the dose, as small as 50 microns prevent the ends of the layer 3 is found on the surface of the object.

FIG. 6 illustrates a multilayer dose corresponding to the second embodiment of the invention. This dose 1 consists of a thin layer of functional resin 3 trapped in a resin 2. The thin layer of functional resin 3 has two free ends 4 and 5; the first end 4 being completely trapped in the resin 2, so that the end 4 is totally absent from the surface of said dose; the second end 5 being present on the surface of said dose. The first end 4 is separated from the surface of said dose by a distance 6 sufficient so that this end is also absent from the surface of the molded object. The functional layer 3 is disposed in the dose so that said layer 3 is distributed throughout the molded object without said layer 3 appearing on the surface of the wall of said object in places where hygiene constraints are important.

Figure 7 shows a multilayer package obtained from the compression in a mold of the dose shown in Figure 6. This package has the thin functional layer 3 completely absent from the surface 10 of the wall of said package in contact with the packaged product. The functional layer 3 forms a fold close to the periphery of said package; said fold and said end 4 being totally trapped in the wall of the package. The end 5 of the functional layer 3 is present at the outer surface 11 of the package; said outer surface 11 not being in contact with the packaged product. Layer 3 is present only on a very small part of the surface of the package; this surface generally representing less than 1% of the total surface area, and preferably less than 0.1% of the total area, given the small thickness of said layer 3. Several multilayer doses corresponding to the first or second mode of the invention are described by way of example.

An example of a dose corresponding to the first embodiment of the invention is illustrated in FIG. 8. This dose comprises a thin functional layer 3 trapped in a resin 2 forming the dose. The functional layer is trapped both laterally and at its ends 4 and 5, so that the functional layer 3 is completely absent from the surface of the dose. The dose comprises an orifice 8 centered on the axis of symmetry.

FIG. 9 shows a tube shoulder obtained by compression in a mold of the dose illustrated in FIG. 8. The thin layer 3 completely absent from the inner and outer surface 10 1 of said shoulder is found; the layer 3 forming a fold at the periphery of the shoulder and the ends 4 and 5 of said layer 3 being close to the orifice 9 of said object.

FIG. 10 illustrates a dose comprising an orifice and produced according to the second embodiment of the invention. This dose 1 consists of a thin layer of functional resin 3 trapped in a resin 2. The thin layer of functional resin 3 has two free ends 4 and 5; the first end 4 being totally trapped in the resin 2; the second end 5 being present on the surface of said dose.

FIG. 11 shows a tube shoulder obtained by compression in a mold of the dose illustrated in FIG. 10. The thin layer 3 is completely absent from the surface of the shoulder 10, said surface 10 being inside the tube and being in contact with the packaged product. The layer 3 forms a fold at the periphery of the shoulder and is totally trapped inside the wall of the tube. The end 5 of the layer 3 is present on the outer surface 11, the surface 11 being on the outside of the package.

FIG. 12 shows another example of a particularly advantageous dose for producing multilayer objects. The imprisonment of the ends 4 and 5 of the thin functional layer 3 inside the resin 2 makes it possible to obtain an object totally free of said layer 3 at the surface. These doses are particularly advantageous for producing multilayer objects with or without an orifice.

Figure 13 illustrates a dose geometry, having a cavity at its center. This multilayer dose comprises a thin functional layer 3 trapped in a first resin 2 forming at least 80% of said dose. The end 4 of the layer 3 is at a distance 6 from the surface of the dose, so that during the compression of said dose, the end 4 of said layer 3 is absent from the surface of the object.

FIG. 14 shows a multilayer dose 1 comprising a thin functional layer 3 trapped at least partially in a first resin 2, said resin 2 representing at least 80% of the volume of the dose. The layer 3 forms the envelope of a revolution body centered on the axis of symmetry of said dose. According to the first embodiment of the invention, the ends 4 and 5 of the layer 3 are also trapped in the first resin 2, so that the layer 3 is totally trapped in the resin 2. According to the second embodiment of the invention only the end 5 of the layer 3 is not trapped in the resin 2, so that after compression of the dose in a mold, only the end 5 of the layer 3 is found on the surface of the molded object .

FIG. 15 illustrates another exemplary dose comprising two thin functional layers 3 'and 3 "centered on the axis of symmetry of said dose and trapped at least partly in a first resin 2. According to the first embodiment of the invention, layer 3 is totally trapped in the resin 2, even at its ends 4 ', 5' and 4 ", 5". According to the second embodiment of the invention, only the ends 5 'and 5 "of the layers 3' and 3 '"are not trapped in resin 2. The objects shown in FIGS. 9 and 11 were made with a thin layer of barrier resin (EVOH) trapped in a polyethylene (PE) resin. These objects have a high impermeability to oxygen or aroma.

For simplicity of the disclosure of the invention, the figures have been deliberately represented with only a functional layer 3 trapped in a second resin 2. It is known that the combination of only two resins generally does not allow to obtain a sufficient adhesion to the interface between the two resins. Also, it is common to use adhesive intermediate layers to associate resins of different nature while ensuring a good level of adhesion between the layers. Thus, the insertion of an adhesive layer on either side of the barrier layer avoids the possible problems of delamination or decohesion in the multilayer objects. The adhesive and barrier layers are parallel and in small quantities. The set of adhesive layers forming the functional layer 3 generally represents an amount of resin less than 15% of the total volume of resin forming the dose, and preferably an internal quantity of 10%. The present invention is therefore not limited to 3-layer doses as shown in FIGS. 4, 6, 8, 10, 12, 13 and 14 but more generally comprise 5 or more layers.

The resins used in the context of the invention correspond to the thermoplastic resins commonly used, and more particularly those used in the packaging sector. Among the barrier resins that can be used to form the functional layer 3, mention may be made of ethylene vinyl alcohol copolymers (EVOH), polyamides such as nylon-MXD6, acrylonitrile methyl acrylate copolymers (BAREX), fluoropolymers such as PVDF. There are also some resins that can be used to form the structure 2 of the object: polyethylene (PE), polypropylene (PP), polystyrene (PS), polyamide (PA), polyester (PET). This list is not exhaustive. When choosing resins, it is important to select products with similar viscosities. In general, it is preferable to use resins which at the working temperature have a viscosity ratio of less than 10, and preferably a viscosity ratio of less than 3 will be selected. The compression molding method involves feeding a multilayer dose of synthetic resins in the molten state into the cavity of a mold; forming the object by compression molding said dose in the cavity of said mold; to cool the object then to unmold it.

The invention makes it possible to produce objects with a very thin functional layer, said functional layer being able to represent less than 5% of the volume of the object.

The method for producing multilayer objects described below is particularly advantageous for producing objects such as plugs, lids, preforms or tube shoulders. This method can also be used advantageously to produce preforms in the form of slabs; these wafers are then used in thermoforming or blowing thermoforming to form multilayer objects.

The doses presented above can be carried out according to several methods.

One method is to co-extrude the resins to form a multilayer structure; and at least the functional layer 3 is intermittently extruded.

An example of this method is shown in Figure 16. A multilayer rod is coextruded without interruption; the flow rate of the functional layer 3 being periodic and intermittent, the periodicity of the layer 3 and the cut of said rod being identical. This method is particularly advantageous for producing multilayer doses at a high rate. This method is advantageously used to produce doses having the functional layer 3 totally trapped in the resin 2. A second embodiment of multilayer doses according to this first method is illustrated in FIG. 17. A multilayer rod is coextruded in a discontinuous manner, so that the overall coextruded resin flow rate varies between a maximum value and a zero value; the quantity of material dosed during a period corresponding to a dose. The functional layer 3 is fed for a shorter time than the resin 2 so that the ends of the layer 3 are trapped in the resin 2.

A second method of multilayer dose manufacturing according to the invention consists in trapping at least one end of the layer 3 in the resin 2; said imprisonment being made outside the extrusion tool.

An example of this second method is illustrated in FIG. 18. A knife 9 periodically cuts the multilayer flow at the outlet of the extrusion tool 8, thus forming doses 1. The dose 1 comprises a functional layer 3 trapped in the resin 2, except at the end 5 of said layer 3. The end 4 of said layer 3 is trapped in the resin 2; the imprisonment being made during the cutting of the multilayer rod by the knife 9. The geometry of the knife 9, associated with the cutting movement of said knife causes the resin 2 which traps the end 4 of the layer 3.

Another embodiment of multilayer doses according to the second method is illustrated in FIG. 19. Doses are formed from a tubular multilayer flow. At the outlet of the extrusion tool 8, the knife 9 periodically cuts the dose 1 and simultaneously traps the end 4 of the functional layer 3 in the resin 2.

Similar methods can be used to trap one or both ends of the layer 3 in the resin 2. These methods can be applied during the cutting of the dose, during its transfer into the mold cavity or inside the mold. molding device. These methods have one thing in common: to modify the initial geometry of the dose in order to drive the resin 2, and to trap the end of the layer 3. In the examples presented here, the doses and the objects are of simple geometry, but it goes without saying that the invention concerns any dose and object geometry.

The objects obtained according to the invention comprise a functional layer 3 forming at least one fold at the periphery of the object. Objects also having a second fold close to the axis of symmetry of the object can be obtained. An arrangement of the zigzag functional layer can be obtained in the object.

There are many provisions of functional layer 3 in the dose. It may be advantageous to arrange the functional layer 3 in the dose so that said functional layer 3 forms the envelope of a body of revolution centered on the axis of symmetry. When the distance from the functional layer 3 to the axis of symmetry is variable, advantageous multilayer objects can be obtained.

Doses comprising a plurality of functional layers 3 may also be used; said functional layers being all centered on the axis of symmetry of said dose. The multilayer objects obtained are characterized in that the functional layers overlap at least partially, and each form at least one fold.

Other dose geometries can be used. It has been observed that doses having a part of their concave surface are particularly advantageous. Such dose geometries facilitate a good distribution of the functional layer in the multilayer object.

Claims

claims

1. Dose of multilayer synthetic resin for producing multilayer objects by compression molding; said dose having an axis of symmetry and comprising a first synthetic resin (2) and at least one thin functional layer (3) of synthetic resin forming the outer envelope of a body of revolution defined about said axis of symmetry; said body of revolution comprising two ends arranged in a direction parallel to the axis of symmetry; said dose being characterized in that the functional layer (3) is trapped in said first synthetic resin (2), totally or in such a way that at most only one of said ends is not trapped in said first resin (2) .

2. Dose according to claim 1, characterized in that the functional layer (3) is totally trapped in the first resin (2).

3. Dose according to any one of the preceding claims characterized in that the thin functional layer (3) itself forms a multilayer structure comprising a barrier resin layer trapped between two layers of adhesive resin.

4. Dose according to any one of the preceding claims characterized in that the two ends of the functional layer are open.

5. Dose any one of claims 1 to 3 characterized in that one two ends of the functional layer is open and the other end is closed.

6. Dose according to any one of claims 1 to 3 characterized in that the two ends of the functional layer are closed.

A multilayer object obtained by compression-molding from a dose according to any one of claims 1 to 6; said object having an inner face and an outer face, said inner face defining the inner portion of a package; said object being formed of said first synthetic resin (2) and said thin functional layer (3); said functional layer (3) being trapped in the wall of said object and forming a fold; said object being characterized in that the functional layer (3) is totally absent from said inner face.

The method of manufacturing doses as defined in any one of claims 1 to 6 including a step wherein the resins are coextruded to form a multilayer flow; said flow being periodically cut to form individual portions; said portions being transferred into a compression mold; characterized in that said portions are deformed so as to cover at least one end of the functional layer (3) with the first synthetic resin (2).

9. Method according to the preceding claim characterized by the fact that said portions are deformed during cutting.

10. Method according to claim 8 characterized in that one deforms said portions during their transfer into the mold.

11. Method according to claim 8 characterized in that one deforms said portions once they are in the mold.

12. A method of manufacturing doses as defined according to any one of claims 1 to 6 comprising a step during which resins are coextruded in the same direction; characterized in that it comprises a covering step in which said first resin (2) is exclusively extruded so as to cover at least one end of said functional layer (3).

13. Method according to the preceding claim characterized in that one applies successively a recovery step, a coextrusion step and a recovery step so as to completely trap said functional layer (3).